Method for producing a decorated wall or floor panel

Abstract

A method for producing a decorated wall or floor panel, comprises the steps of: providing a pourable carrier material, in particular a granulate; placing the carrier material between two belt-like conveying means; forming the carrier material under the influence of temperature to form a web-shaped carrier; compressing the carrier; treating the carrier under the influence of pressure with use of a twin belt press at a first temperature T1 while forming a first compression factor K1 of the carrier; treating the carrier under the influence of pressure at a second temperature T2 while forming a second compression factor K2 of the carrier, wherein T2<T1 and wherein K2<K1; optionally cooling the carrier; optionally applying a decorative subsurface onto at least part of the carrier; applying a decorative template onto at least part of the carrier; and applying a protective layer onto at least part of the decoration.

The invention claimed is: 
     
       1. A method for producing a decorated wall or floor panel, comprising the method steps:
 a) providing a pourable carrier material; 
 b) placing the carrier material between two belt conveying means; 
 c) forming the carrier material under the action of temperature while forming a carrier sheet; 
 d) compressing the carrier; 
 e) treating the carrier under the action of pressure by use of a twin belt press at a temperature T1 while reducing the thickness of the carrier by compression factor K1; 
 f) subsequently treating the carrier under the action of pressure at a temperature T2 while reducing the thickness of the carrier by a compression factor K2, wherein T2<T1, and wherein K2<K1, wherein T1 is in a range of between ≥150° C. and ≤190° C., T2 is in a range between ≥100° C. and ≤150° C., K1 is in a range between >0 and ≤0.3, and K2 is in a range between >0 and ≤0.2; 
 g) optionally cooling the carrier; 
 h) optionally applying a decorative subsurface onto at least a portion of the carrier; 
 i) applying a decoration reproducing a decorative template onto at least a portion of the carrier; and 
 j) applying a protective layer onto at least a portion of the decoration. 
 
     
     
       2. The method according to  claim 1 , wherein the temperature T1 and the temperature T2 are set by tempering means acting separate from each other. 
     
     
       3. The method according to  claim 1 , wherein the method steps e) and f) are carried out in a common twin belt press. 
     
     
       4. The method according to  claim 1 , wherein the method steps e) and f) are carried out in two pressing means separated from each other. 
     
     
       5. The method according to  claim 4 , wherein the method step f) is carried out in a twin belt press or in a calender. 
     
     
       6. The method according to  claim 1 , wherein a carrier material based on a plastic or a wood-plastic composite material is provided. 
     
     
       7. The method according to  claim 1 , wherein the carrier is temporarily stored between method steps e) and f). 
     
     
       8. The method according to  claim 1 , wherein the carrier is cooled down to a temperature T3 between method steps e) and f), wherein T3<T1 and wherein T3<T2. 
     
     
       9. The method according to  claim 1 , wherein the carrier prior or subsequently to method step f) is heated to a temperature which is above the crystallization temperature of a plastic component present in the carrier. 
     
     
       10. The method according to  claim 1 , wherein prior to method step e) an anti-adhesive means is disposed such that at least within the twin belt press it is disposed between the carrier and the conveying means. 
     
     
       11. The method according to  claim 1 , wherein the carrier is cooled prior to method step e) in particular below the melting point or the softening point of a plastic component of the carrier. 
     
     
       12. The method according to  claim 1 , wherein the carrier subsequently to method step f) is heated to a temperature above the crystallization temperature of a plastic present in the carrier. 
     
     
       13. The method according to  claim 1 , wherein method step f) is carried out in a twin belt press, wherein belt conveying means used in method step f) each comprise a steel belt coated with polytetrafluoroethylene. 
     
     
       14. The method according to  claim 1 , wherein a method step d) is carried out by use of an S-roller. 
     
     
       15. An apparatus for carrying out a method according to  claim 1 , comprising;
 two endless belt conveying means; 
 a discharge unit for applying a carrier material between the belt conveying means; 
 a molding unit for forming a carrier sheet from the carrier material; 
 a first pressing means for compressing the carrier; 
 a twin belt press as a pressing means for treating the carrier under the action of pressure at a temperature T1; 
 optionally a further pressing means, 
 wherein the apparatus is further configured such that the carrier after the treatment in the twin belt under the action of pressure at a temperature T1 can be treated further at a temperature T2 in the twin belt press or in the further pressing means such that a compression factor K1 can be set at the temperature T1 and a compression factor K2 can be set at the temperature T2, wherein K2<K1, wherein T1 can be set in a range of between ≥150° C. and ≤190° C., T2 can be set in a range between ≥100° C. and ≤150° C., K1 can be set in a range between >0 and ≤0.3, and K2 can be set in a range between >0 and ≤0.2.